Introduction to Nondestructive Testing: A Training Guide, 2nd Edition

Preface.

1 Introduction.

1.1 Digital Technology.

1.2 Smaller Is Better.

1.3 Medical Marvels.

1.4 Improving Shuttle Safety.

1.5 Airport Security.

1.6 Process Control.

1.7 Instrument Synchronization with PXI.

1.8 PCI vs. PXI.

1.9 60,000-Mile-High Elevator.

1.10 Proliferation of Information.

2 Acoustic Emissions.

2.1 Principles and Theory.

2.2 Signal Propagation.

2.3 Physical Considerations.

2.4 The AE Process Chain.

2.5 Time Considerations.

2.6 AE Parameters.

2.7 The AE Measurement Chain.

2.8 Vallen AMSY-5 High-Speed AE System.

2.9 Location Calculation and Clustering.

2.10 Advantages and Limitations of AE Testing.

2.11 AMSY-5 Main Features.

2.12 AE Transducers.

2.13 Kistler Piezotron® Acoustic Emission Sensors and Couplers.

2.14 AE Sensor Construction.

2.15 Summary of AE Sensor Features.

2.16 Technical Specifications—8152B2 Sensor.

2.17 AE Coupler Features.

2.18 Technical Specifications—5125B Coupler.

2.19 Acoustic Emission Technology.

2.20 AE Applications.

2.21 AE Theory.

2.22 Applications.

2.23 Advanced Equipment.

2.24 Codes, Standards, Practices, Guidelines, and Societies.

2.25 Application and Product-Specific Procedures.

2.26 Impact-Echo Method.

2.27 Technical Specifications.

2.28 Applications.

3 Electromagnetic Testing Method.

3.1 Eddy Current Theory.

3.2 Magnetic Flux Leakage Theory.

3.3 Eddy Current Sensing Probes.

3.4 Flux Leakage Sensing Probes.

3.5 Factors Affecting Flux Leakage.

3.6 Signal-to-Noise Ratio.

3.7 Test Frequency.

3.8 Magnetization for Flux Leakage Testing.

3.9 Coupling.

3.10 Eddy Current Techniques.

3.11 Instrument Design Considerations.

3.12 UniWest US-454 EddyView.

3.13 Institut Dr. Foerster.

3.14 Magnetic Flux Leakage Testing.

3.15 Applications.

3.16 Use of Computers.

3.17 Barkhausen Noise/Micromagnetic Testing.

3.18 Early Applications.

3.19 Principles of Measurement.

3.20 Equipment.

3.21 Technical Specifications.

3.22 Calibration and Testing.

3.23 Current Applications.

3.24 General Applications.

3.25 Electromechanical Acoustic Transducers (EMATs).

3.26 Basic Theory of Operation.

3.27 Recent Applications and Developments.

3.28 Alternating Current Field Measurement (ACFM) Method.

3.29 ACFM Principles of Operation.

3.30 Probe Design.

3.31 Applications.

4 Laser Testing Methods.

4.1 Introduction.

4.2 Disadvantages.

4.3 Main Advantages.

4.4 Laser Theory.

4.5 Laser Safety.

4.6 Laser Classification.

4.7 Training.

4.8 Profilometry Methods.

4.9 Basic TV Holography/ESPI Interferometry.

4.10 Nanometric Profiling Measurements.

4.11 Conoscopic Holography.

4.12 Confocal Measurement.

4.13 NanoSurf Confocal Microscopy.

4.14 3D Confocal Microscopy.

4.15 Nanometric Profiling Applications.

4.16 Scanning Laser Profilometry.

4.17 Laser-Scanned Penetrant Inspection (LSPITM-Patent Pending).

4.18 Advanced Techniques.

4.19 Natural and External Excitation.

4.20 Strain/Stress Measurement.

4.21 Longer Range 3D Speckle Interferometry System.

4.22 Nondestructive Testing (NDT).

4.23 Shearography.

4.24 Portable Shearography System.

4.25 Feltmetal Inspection System.

4.26 Optional Applications.

4.27 Optical Inspection Systems.

4.28 ARGUS.

4.29 TRITOP.

4.30 System Advantages.

4.31 Portable Measuring System Technique.

4.32 Dynamic TRITOP.

4.33 Other Laser Methods.

5 Leak Testing Methods.

5.1 Introduction.

5.2 Fundamentals.

5.3 Ultrasonic Leak Testing.

5.4 Bubble Leak Testing.

5.5 Dye Penetrant Leak Testing.

5.6 Pressure Change Leak Testing.

5.7 Helium Mass Spectrometer Leak Testing.

5.8 Mass Spectrometer Leak Detector.

5.9 MSLD Subsystems.

5.10 Vacuum System Configurations.

5.11 Electronics.

5.12 Methods of Leak Detection.

5.13 Vacuum Testing Method (Outside-In).

5.14 Pressure Test Method (Inside-Out).

5.15 Accumulation Testing Method.

5.16 Vacuum Systems.

5.17 Pressurized Systems.

5.18 MSLD Configurations.

5.19 Calibration.

5.20 Radioisotope Tracer Leak Testing.

5.21 Bubble Leak Testing.

5.22 Pressure Change Leak Testing.

5.23 Pressure Change Measurement Testing.

5.24 Leakage Rate and Flow Measurement Testing.

5.25 Nuclear Reactor Systems.

5.26 Halogen Diode Leak Testing.

5.27 “Sniffer” Techniques.

5.28 VIC MSLD Leak Detectors.

5.29 MSLD Subsystems.

5.30 Operating Sequence (MS-40 and MS-40 Dry).

5.31 Calibration Sequence (MS-40 and MS-40 Dry).

6 Liquid Penetrant Tests.

6.1 Introduction.

6.2 Processing.

6.3 Test Methods.

6.4 Advantages and Disadvantages of Various Methods.

6.5 Test Equipment.

6.6 Penetrant Materials.

6.7 System Comparisons.

6.8 Applications.

6.9 Measurement of UV and Visible Light.

6.10 Automatic and Semiautomatic Penetrant Testing Methods.

7 Magnetic Particle Testing.

7.1 Magnetic Principles.

7.2 Magnets and Magnetic Fields.

7.3 Discontinuities and Defects.

7.4 Induced Magnetic Fields.

7.5 Circular and Longitudinal Fields.

7.6 Selection of Magnetizing Method.

7.7 Commercial Equipment.

7.8 Wet and Dry Particle Inspection.

7.9 MT Improvements.

7.10 Applications.

7.11 Residual Fields and Demagnetization.

7.12 Magnetic Flux Strips.

7.13 Hall Effect Gaussmeter.

7.14 The Hysteresis Curve.

7.15 Selection of Equipment.

7.16 Advantages and Disadvantages of the Method.

7.17 Magnetic Rubber Inspection.

7.18 Underwater MRI.

7.19 Magnetic Penetrameters.

7.20 Automatic and Semiautomatic Inspection.

7.21 Magwerks Integrated System Tracking Technology.

7.22 Discontinuities and Their Appearances.

7.23 Nonrelevant Indications.

8 Neutron Radiographic Testing.

8.1 Introduction.

8.2 Physical Principles.

8.3 Neutron Radiation Sources.

8.4 Neutron Activation Analysis.

8.5 Ward Center TRIGA Reactor.

8.6 Radiation Hazards and Personal Protection.

8.7 Radiation Detection Imaging.

8.8 Electronic Imaging.

8.9 Nonimaging Detectors.

8.10 Neutron Radiographic Process.

8.11 Interpretation of Results.

8.12 Other Neutron Source Applications.

8.13 Neutron Level Gauges.

8.14 Californium-252 Sources.

8.15 Neutron Radioscopic Systems.

9 Radiographic Testing Method.

9.1 Industrial Radiography.

9.2 Work Practices.

9.3 Time—Distance—Shielding—Containment.

9.4 Regulatory Requirements.

9.5 Exposure Devices.

9.6 State and Federal Regulations.

9.7 Basic Radiographic Physics.

9.8 Fundamental Properties of Matter.

9.9 Radioactive Materials.

9.10 Types of Radiation.

9.11 Interaction of Radiation with Matter.

9.12 Biological Effects.

9.13 Radiation Detection.

9.14 Radiation Sources.

9.15 Portable Linear Accelerators.

9.16 Special Radiographic Techniques.

9.17 Standard Radiographic Techniques.

9.18 The Radiograph.

9.19 Fluoroscopy Techniques.

9.20 Flat Panel Digital Imaging Systems.

9.21 Flat Panel Systems vs. Fuji Dynamix CR Imaging System.

9.22 Industrial Computed Tomography.

9.23 Automatic Defect Recognition.

9.24 The Digitome Process.

9.25 Manufacturing Processes and Discontinuities.

9.26 Other Isotope Applications.

10 Thermal/Infrared Testing Method.

10.1 Basic Modes of Heat Transfer.

10.2 The Nature of Heat Flow.

10.3 Temperature Measurement.

10.4 Common Temperature Measurements.

10.5 Color Change Thermometry.

10.6 Temperature Sensors with External Readouts.

10.7 Infrared Imaging Energy.

10.8 Heat and Light Concepts.

10.9 Pyrometers.

10.10 Infrared Imaging Systems.

10.11 Spacial Resolution Concepts.

10.12 Infrared Testing Method.

10.13 High-Performance Thermal Imager for Predictive Maintenance.

10.14 High-Performance Radiometric IR System.

10.15 Mikron Instrument Company, Inc.

10.16 Mikron 7200V Thermal Imager and Visible Light Camera.

10.17 High-Speed IR Line Cameras.

10.18 Other Thermal Testing Methods.

11 Ultrasonic Testing.

11.1 Introduction.

11.2 Definition of Acoustic Parameters of a Transducer.

11.3 Noncontacting Ultrasonic Testing.

11.4 Ultrasonic Pulsers/Receivers.

11.5 Multilayer Ultrasonic Thickness Gauge.

11.6 Conventional Ultrasound.

11.7 Ultrasonic Testing Equipment.

11.8 Time-of-Flight Diffraction (TOFD).

12 Vibration Analysis Method.

12.1 Introduction.

12.2 Principles/Theory.

12.3 Sources of Vibration.

12.4 Noise Analysis.

12.5 Stress Analysis.

12.6 Modal Analysis.

12.7 Vibration Analysis/Troubleshooting.

12.8 Transfer Functions.

12.9 Predictive Maintenance.

12.10 Failure Analysis.

12.11 Impact Testing and Frequency Response.

12.12 Pass and Fail Testing.

12.13 Correction Methods.

12.14 Machine Diagnosis.

12.15 Sensors.

12.16 Rolling Element Bearing Failures.

12.17 Bearing Vibration/Noise.

12.18 Blowers and Fans.

12.19 Vibrotest 60 Version 4.

12.20 Signal Conditioning.

12.21 Equipment Response to Environmental Factors.

12.22 Data Presentation.

12.23 Online Monitoring.

12.24 Portable Noise and Vibration Analysis System.

12.25 Laser Methods.

12.26 TEC’s Aviation Products.

13 Visual and Optical Testing.

13.1 Fundamentals.

13.2 Principles and Theory of Visual Testing.

13.3 Selection of Correct Visual Technique.

13.4 Equipment.

13.5 Fiberscopes and Videoscopes.

13.6 SnakeEyeTM Diagnostic Tool.

13.7 Industrial Videoscopes.

13.8 Projection Microscopes.

13.9 The Long-Distance Microscope.

13.10 InfiniMaxTM Long-Distance Microscope.

13.11 Remote Visual Inspection.

13.12 Robotic Crawler Units.

13.13 Pipe and Vessel Inspections/Metal Joining Processes.

13.14 Ocean Optics Photometers.

14 Overview of Recommended Practice No. SNT-TC-1A, 2001 Edition.

14.1 Purpose.

14.2 NDT Levels of Qualification.

14.3 Recommended NDT Level III Education, Training, and Experience.

14.4 Written Practice.

14.5 Charts.

14.6 Recommended Training Courses.

Appendix 1: Bibliography of Credits.

Appendix 2: Company Contributors.

Index.